US8024993B2 - Bicycle component and method for manufacturing such a component - Google Patents

Bicycle component and method for manufacturing such a component Download PDF

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Publication number
US8024993B2
US8024993B2 US10/861,206 US86120604A US8024993B2 US 8024993 B2 US8024993 B2 US 8024993B2 US 86120604 A US86120604 A US 86120604A US 8024993 B2 US8024993 B2 US 8024993B2
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Prior art keywords
structural fibers
component
loops
seats
continuous structural
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US10/861,206
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US20050012298A1 (en
Inventor
Giuseppe Dal Prà
Paolo Dettori
Mauri Feltrin
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Campagnolo SRL
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Campagnolo SRL
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Assigned to CAMPAGNOLO S.R.L. reassignment CAMPAGNOLO S.R.L. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: DAL PRA, GIUSEPPE, DETTORI, PAOLO, FELTRIN, MAURI
Publication of US20050012298A1 publication Critical patent/US20050012298A1/en
Priority to US11/860,220 priority Critical patent/US20080054715A1/en
Priority to US13/245,351 priority patent/US10105916B2/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/86—Incorporated in coherent impregnated reinforcing layers, e.g. by winding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/081—Combinations of fibres of continuous or substantial length and short fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/20—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres
    • B29C70/202—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres arranged in parallel planes or structures of fibres crossing at substantial angles, e.g. cross-moulding compound [XMC]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/22—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least two directions forming a two-dimensional [2D] structure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62K—CYCLES; CYCLE FRAMES; CYCLE STEERING DEVICES; RIDER-OPERATED TERMINAL CONTROLS SPECIALLY ADAPTED FOR CYCLES; CYCLE AXLE SUSPENSIONS; CYCLE SIDECARS, FORECARS, OR THE LIKE
    • B62K19/00—Cycle frames
    • B62K19/02—Cycle frames characterised by material or cross-section of frame members
    • B62K19/16—Cycle frames characterised by material or cross-section of frame members the material being wholly or mainly of plastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62M—RIDER PROPULSION OF WHEELED VEHICLES OR SLEDGES; POWERED PROPULSION OF SLEDGES OR SINGLE-TRACK CYCLES; TRANSMISSIONS SPECIALLY ADAPTED FOR SUCH VEHICLES
    • B62M3/00—Construction of cranks operated by hand or foot
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/06—Rods, e.g. connecting rods, rails, stakes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3091—Bicycles
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24132—Structurally defined web or sheet [e.g., overall dimension, etc.] including grain, strips, or filamentary elements in different layers or components parallel
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
    • Y10T428/249933—Fiber embedded in or on the surface of a natural or synthetic rubber matrix
    • Y10T428/249939—Two or more layers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T74/00—Machine element or mechanism
    • Y10T74/21—Elements
    • Y10T74/2164—Cranks and pedals

Definitions

  • the present invention relates to a bicycle component that is particularly suitable for use in the assembly of bicycle parts that deal with high specific pressures.
  • the invention also relates to a method of manufacturing such a component.
  • the exemplary component described is a pedal crank
  • the invention also extends to other bicycle components with requirements similar to those of a pedal crank, for example, a seat tube.
  • a suitable composite material is described in U.S. Pat. No. 4,339,490. Sheets formed of a resin matrix have differently shaped small pieces of structural fibers, of a size between 1 and 100 mm, orientated randomly into the sheet.
  • the use of such a type of composite material for molding provides a compromise between obtaining good strength characteristics, typical of the structural fibers, and the need to keep a sufficient fluidity during molding.
  • the size of the small pieces allows the composite material to flow sufficiently uniformly inside the mold, creating a homogenous pedal crank body.
  • the molding technique used provides for arranging a predetermined amount of composite material in the central zone of the mold and, during the molding step, making such a composite material flow until the entire mold is filled, even in the end areas with the arranged metal inserts.
  • the composite material flows around the metal inserts following two distinct flow paths that meet near the end of the pedal crank, completely encasing the inserts.
  • the two-pronged flow causes a disadvantageous area of discontinuity in the joint points of the two flows.
  • a disadvantage stems from the greater fluidity of the resin with respect to that of the structural fibers and due to the long route (from the center to the end of the mold), the end zones of the pedal crank have a greater percentage of resin with respect to the percentage in the rest of the pedal crank and, consequently lower strength with respect to the rest of the body.
  • a specific drawback encountered in pedal cranks obtained by molding composite material having small pieces of structural fibers is the breakage of the pedal crank in its center area. The occurrence of such a drawback is due to the fact that such a composite material with small pieces does not ensure sufficient strength in such an area of the pedal crank.
  • the invention in a first aspect, relates to a bicycle component comprising an elongated body having spaced apart first and second ends, each end defining a seat for mechanical coupling with an element of the bicycle.
  • the component further comprises at least two layers of structural fibers incorporated in a matrix of polymeric material, at least one of the layers having randomly arranged structural fibers. At least one of the layers of structural fibers partially surround each of the seats, establishing mechanical continuity between them.
  • the invention comprises a method for manufacturing a bicycle component comprising an elongated body consisting of structural fibers incorporated in a matrix of polymeric material and having, in an end part thereof, a seat for mechanical coupling with an element of the bicycle, said method comprising the steps of:
  • FIG. 1 represents a schematic isometric view of the component of the invention.
  • FIG. 2 represents a section view from above of the component of FIG. 1 .
  • FIG. 3 represents an alternate embodiment of the component of FIG. 1 .
  • FIG. 4 represents an elevated section view of the component of FIG. 3 .
  • FIGS. 4A , 4 B and 4 C represent elevated section views of alternate embodiments of the component of FIG. 3 .
  • FIG. 5 represents another alternate embodiment of the component of FIG. 1 .
  • FIGS. 6 to 11 represent different isometric views of the semi-finished product of the invention.
  • FIG. 12 represents an exploded isometric view of the mold used for manufacturing the component of the invention.
  • FIG. 13 represents an isometric view of a detail of FIG. 12 .
  • FIG. 14 represents an exploded isometric view of a mold used for manufacturing an alternate embodiment of the component of the invention.
  • FIG. 15 represents an isometric view of an alternate embodiment relative to the progression of the continuous layers of structural fibers in a branched pedal crank.
  • FIG. 16 represents a plan view of FIG. 15 .
  • FIG. 17 represents another alternate embodiment relative to the progression of the continuous layers of structural fibers in a branched pedal crank.
  • FIG. 18 represents an isometric view of a further alternate embodiment relative to the progression of the continuous layers of structural fibers in a branched pedal crank.
  • the layers of continuous structural fibers 13 and 14 are made with unidirectional fibers orientated substantially parallel to the middle plane ⁇ through the component, in this case a pedal crank 1 .
  • Middle plane ⁇ is a substantially flat surface that intersects the pedal crank 1 longitudinally and divides it substantially in half along its height H. Given the typical shape of the pedal crank 1 , such a surface is slightly curved when one moves from one end 11 to the other 12 of the pedal crank 1 .
  • said continuous structural fibers are chosen from the group consisting of carbon fibers, glass fibers, boron fibers, aramidic fibers, ceramic fibers, carbon fiber being preferred.
  • the layers of continuous structural fibers 13 and 14 surround the end zones 9 and 10 of seats 5 and 6 , in a single closed loop 15 of unidirectional fibers that extend longitudinally along the body 2 of the pedal crank 1 .
  • This configuration could be different, like for example a series of unidirectional structural fibers surrounding the two seats 5 and 6 according to a typical “figure-eight” configuration.
  • the layers of continuous structural fibers 13 and 14 are provided only in a part of the thicknesses S 1 and S 2 of the end zones 9 and 10 and can, at most, also be reduced to a single layer.
  • Such layers 13 and 14 are provided only for a part of the height H of the pedal crank component 1 and are confined in height by means of an annular retainer element 16 , coaxial to the insert 7 .
  • the arrangement of a limited number of layers 13 and 14 of fibers in the pedal crank 1 implies that the inserts 7 , 8 are substantially covered with the composite material 18 with which the body 2 of the pedal crank 1 is formed, as can be seen more clearly in FIG. 2 .
  • FIG. 4A differs from the solution shown in FIG. 4 for the fact that the body 2 has a core C filled with a material having a lower specific weight than the composite material 38 .
  • the core C is removed after molding, so that the weight of the pedal crank is reduced.
  • FIG. 5 shows an alternate embodiment of the arrangement of the layers of continuous structural fibers 53 and 54 wherein the layers completely and separately surround the two seats 45 and 46 and the corresponding metal inserts 47 and 48 .
  • the component 1 has, at its end parts 3 and 4 , respective seats 5 and 6 for mechanical coupling with a bottom bracket and with a pedal of the bicycle.
  • the seats 5 and 6 incorporate cylindrical metal inserts 7 and 8 in which holes, not shown, are formed to connect the inserts 7 and 8 the bottom bracket and to the pedal, respectively.
  • the seats 5 and 6 comprise a hole of a suitable shape adapted to allow the direct connection of the pedal crank to the bottom bracket and to the pedal or else the subsequent insertion of metal inserts.
  • the layers of continuous structural fibers can take different shapes and sizes.
  • such layers can extend, at the end zone, for the entire height H of the pedal crank 1 .
  • such layers can be made of interwoven structural fibers according to at least two incident directions to make a fabric.
  • such a fabric comprises a majority of fibers orientated according to a direction parallel to the middle plane of the pedal crank 1 .
  • the pedal crank 1 and specifically its elongated body 2 , is formed from a semi-finished product, indicated as 60 in FIG. 6 , consisting of three layers. Each of the layers is formed as a sheet of material. As used hereinafter in the description and claims, the term “sheet” refers to a defined thickness of material forming either an individual layer, or one of a plurality of independent or joined layers of a structure.
  • One layer 61 is formed of small lengths of structural fiber 61 a incorporated in a matrix of polymeric material and randomly arranged within the layer 61 and two layers 62 and 63 are formed of continuous structural fibers 62 a and 63 a which are incorporated in a matrix of polymeric material and orientated according to directions which are preferably angled relative to each other.
  • the layers 61 , 62 and 63 overlap one another and give the semi-finished product 60 characteristics of structural strength through the unidirectional fibers 62 a and 63 a and good characteristics of fluidity through the sheeted structure 61 a , this last characteristic being exploited in the molding step of the pedal crank 1 .
  • the small lengths of structural fibers are chosen from the group consisting of carbon fiber, glass fibers, boron fibers, aramidic fibers, and ceramic fibers, carbon fiber being preferred.
  • the polymeric material may be a thermosetting plastic material or a thermoplastic material.
  • FIG. 8 differs from that of FIG. 6 in that the unidirectional fibers 72 a and 73 a are incorporated in the matrix of polymeric material of respective layers 72 and 73 in complementary directions and are respectively orientated at +90° and 0°.
  • the semi-finished product comprises a layer of small lengths of structural fibers 61 a incorporated in a matrix of polymeric material overlapping a single layer 63 formed of continuous structural fibers 63 a orientated on a bias within layer 63 .
  • the semi-finished product comprises a layer of small lengths of structural fibers 61 a and a layer 81 in which the continuous structural fibers 81 a are arranged according to two incident directions and form a fabric configuration.
  • FIG. 11 a semi-finished product formed of five layers is shown.
  • Two layers 91 and 93 are formed of small lengths of structural fibers incorporated in a matrix of polymeric material intercalated in three layers 92 , 94 and 95 formed of continuous structural fibers of adjacent layers in which the fibers are orientated at an angle relative to each other.
  • the semi-finished product 60 used for manufacturing the body 2 of the pedal crank 1 are preferably rolled around a rolling axis before the molding step, as described below. This allows the characteristics of unidirectional strength of the structural fibers to be spatially distributed.
  • FIG. 12 the method for manufacturing the pedal crank 20 shown in FIG. 3 is described. However, it should be understood that the same method can be used for the other embodiments shown or described, for example those of FIGS. 1 and 5 .
  • the method provides for the use of a mold 100 which comprises three parts, two half-shells 101 and 102 and a plunger 103 .
  • the upper half-shell 102 as seen more clearly in the bottom view of FIG. 13 , has a through-opening 104 which allows the passage and the sliding of a press element 105 of the plunger 103 .
  • a first step of the method provides for the formation of an intermediate product 110 comprising the inserts 7 and 8 on which the layers of continuous unidirectional structural fibers are wound in a closed loop configuration 35 .
  • Such an intermediate product 110 can be realized, for example, by winding a long fiber around the inserts 7 , 8 in a number of layers sufficient to obtain a desired thickness and height.
  • the arrangement of the fibers around the insert 7 is defined through retainer loop 16 which confines them in an upper portion of the insert 7 .
  • the intermediate product 110 thus obtained is placed inside the lower half-shell 101 above which the upper half-shell 102 is closed so that its shapings 102 a and 102 b ( FIG. 13 ) are in contact with the heads of the metal inserts 7 and 8 .
  • the semi-finished product 60 previously wound around the rolling axis A is inserted in through opening 104 .
  • the winding of the semi-finished product 60 is arranged so that its outer surface consists of layer 63 formed of unidirectional fibers 63 a .
  • the semi-finished product 60 is pre-heated to ease the subsequent molding.
  • the wound semi-finished product 60 is then located in the zone defined between the inserts 7 and 8 and the inner part of the loop 35 .
  • the presser tool 105 slides inside the opening 104 of the upper half-shell 102 urging the semi-finished product 60 inside the mold 100 .
  • the semi-finished product 60 flows into and uniformly fills the recess defined by the two half-shells 101 and 102 .
  • the closed loop configuration 35 of the unidirectional fibers allows them to keep their continuous configuration even during molding, since the pressure forces applied by the composite material which constitutes the semi-finished product 60 are uniformly distributed along the loop 35 .
  • the mold 100 is heated, according to known techniques, and the materials inside of mold 100 polymerizes in the desired pedal crank structure. Finally, the mold 100 is opened and the pedal crank is removed.
  • any of the semi-finished products described above with reference to FIGS. 6-11 can be used, possibly even in a non-wound configuration. If one wishes to manufacture the pedal crank according to the shape shown in FIG. 5 , it is then advisable for the intermediate product, in this case comprising the inserts on which the unidirectional fibers are individually wound, to undergo a prepolymerization treatment, so that the subsequent molding does not modify the shape of the wound fibers.
  • the component may further comprise a core C as depicted in FIGS. 4A , 4 B and 4 C.
  • a mold 100 is provided, having first and second portions 101 , 102 and plunger 103 as shown in FIG. 12 .
  • An intermediate product 110 is first formed comprising first and second inserts 7 , 8 , about which layers of continuous unidirectional structural fibers are wound in a closed loop configuration 35 .
  • a core C is then arranged in the area within the closed loop of unidirectional structural fibers.
  • the second portion 102 is closed above the first portion so that shapings 102 a and 102 b contact the upper portions of the inserts 7 , 8 .
  • a composite material 38 is inserted into an opening 104 of the second portion 102 of the mold 100 .
  • the composite material 38 comprises small lengths of randomly arranged structural fibers incorporated in a matrix of polymeric material.
  • the plunger 103 is lowered, to force presser 105 into the opening 104 of the second mold portion 102 .
  • the presser 105 forces the composite material 38 into the mold 100 .
  • the composite material 38 flows into the mold 100 and uniformly fills the recess defined by the first and second mold portions 101 , 102 thereby enclosing the core C.
  • the mold With the presser 105 inserted, the mold is heated to a temperature sufficient to polymerize the composite material 38 , thereby producing the desired pedal crank structure.
  • the mold is then opened and the pedal crank is removed.
  • the core C is made of a material having a lower specific weight than the composite material 38 .
  • the weight of the pedal crank with the core enclosed is less than the weight of the pedal crank completely made of composite material.
  • a mold 100 is provided, having first and second portions 101 , 102 and plunger 103 as shown in FIG. 12 .
  • An intermediate product 110 is first formed comprising first and second inserts 7 , 8 , about which layers of continuous unidirectional structural fibers are wound in a closed loop configuration 35 .
  • a core C made of a removable material is then arranged in the area within the closed loop of unidirectional structural fibers. The core helps to maintain the position of the closed loop of unidirectional structural fibers 35 and inserts 7 , 8 .
  • the second portion 102 is closed above the first portion so that shapings 102 a and 102 b ( FIG. 13 ) contact the upper portions of the inserts 7 , 8 .
  • a composite material is inserted into an opening 104 of the second portion 102 of the mold 100 .
  • the composite material 38 comprises small lengths of randomly arranged structural fibers incorporated in a matrix of polymeric material.
  • the plunger 103 is lowered, to force presser 105 into the opening 104 of the second mold portion 102 .
  • the presser 105 forces the composite material 38 into the mold 100 .
  • the composite material 38 flows into the mold 100 and uniformly fills the recess defined by the first and second mold portions 101 , 102 thereby enclosing the core C.
  • the mold With the presser 105 inserted, the mold is heated to a temperature sufficient to polymerize the composite material 38 , thereby producing the desired pedal crank structure. The mold is then opened and the pedal crank is removed.
  • Small openings D 1 , D 2 are formed to remove the core material from the crank structure.
  • the openings D 1 , D 2 may be formed by drilling or other known methods. Two or more openings are preferred to allow for better air exchange between the core and the ambient space which aids in removing the core material.
  • the core material may be sand, a powdered material or a metallic alloy having a low melting point. A core of sand or powdered material can be removed from the crank by falling through the openings D 1 , D 2 under the force of gravity. If a metallic alloy is used as the core, it may be removed simply by heating the crank above the alloy's melting point and allowing the melted core to flow through the openings D 1 , D 2 .
  • Removal of the core material may also be expedited by blowing high-pressured air or fluid through one of the openings. Once the core material has been removed, the openings are then sealed to prevent contaminants from entering the pedal crank. The weight of the pedal crank is further reduced with respect to weight of the pedal crank above described by removal of the core material.
  • a similar method as above for manufacturing the pedal crank of FIG. 4B can be used for manufacturing the pedal crank of FIG. 4C .
  • a support is used for the winding of the unidirectional fibers.
  • the support remains incorporated in the pedal crank whereby a seat can be formed, by machining, for the insertion of a metal insert.
  • the removal of the core material takes place through openings D 3 and D 4 before the insertion of the metal insert.
  • FIG. 14 shows a variation of the mold shown in FIG. 12 which is used for manufacturing a branched pedal crank, commonly known as right pedal crank.
  • a method differs from the previous one in that the semi-finished product, when inserted in the mold 200 , covers the top of the metal insert intended for coupling with the bottom bracket. In this case, the metal insert can be accessed by machining away excess material left over from the molding process. Rather than the metal insert, a support can be used for the winding of the unidirectional fibers. The support remains incorporated in the pedal crank, through machining, for direct coupling with a bottom bracket or the insertion of a metal insert. It is also clear that the mold 200 can be modified so as to obtain a right pedal crank in which the insert intended for coupling with the bottom bracket is also immediately accessible.
  • FIGS. 15 and 16 show the arrangement of the layers of continuous structural fibers 413 a , 413 b , 413 c , 413 d for manufacturing another branched pedal crank, commonly referred to as a right pedal crank.
  • the layers of continuous structural fibers 413 a , 413 b , 413 c , 413 d partially surround the seats 405 a , 405 b , 405 c , 405 d of the end parts 403 a , 403 b , 403 c , 403 d of the spokes which form an arc of circumference of about 180°.
  • These layers are each arranged in such a way as to form respective loops 415 a , 415 b , 415 c , 415 d which close on a central zone 414 where the pedal crank has a suitable seat 406 for connecting to the bottom bracket.
  • intermediate product 400 which is star-shaped.
  • intermediate product 400 is advantageously made through continuous winding, along suitable paths, of continuous layers of unidirectional fibers.
  • the intermediate product 400 can be made either in the mold, i.e., inside the mold shown in FIG. 14 , or it can be made separately using a mask which mirrors the shape of the spokes.
  • the manufacturing of the intermediate product 400 separately allows for prior preheating of the fibers which allows them to be a pre-shaped before the positioning in loco into the mold.
  • the intermediate product 400 is arranged within the mold 200 on a plane overlapping the one in which the closed loop of structural fibers 15 (represented in FIG. 2 ) is arranged, said fibers being arranged along the elongated body 2 of the pedal crank.
  • the configuration thus obtained allows a right pedal crank to be manufactured having the zones intended for coupling with a pedal as well as with a bottom bracket and the ends of the spokes with high structural and mechanical continuity.
  • each seat 405 a , 405 b , 405 c , 405 d can be completely surrounded by structural fibers 413 a , 413 b , 413 c , 413 d by using a closed loop configuration similar to the type shown in FIG. 5 .
  • the same result can be obtained by the manufacturing of a pre-formed product 500 , as shown in FIG. 18 , where the continuous layers of structural fibers associated with the spokes and with the main body are on the same plane and substantially constitute a single element comet-shape.
  • the intermediate product 500 can either be formed within the mold or can be formed separately using a mask which mirrors the shape of the pedal crank.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Textile Engineering (AREA)
  • Combustion & Propulsion (AREA)
  • Transportation (AREA)
  • Moulding By Coating Moulds (AREA)
  • Ropes Or Cables (AREA)
  • Laminated Bodies (AREA)
  • Shafts, Cranks, Connecting Bars, And Related Bearings (AREA)
US10/861,206 2001-02-13 2004-06-04 Bicycle component and method for manufacturing such a component Expired - Fee Related US8024993B2 (en)

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US11/860,220 US20080054715A1 (en) 2001-02-13 2007-09-24 Bicycle wheel hub
US13/245,351 US10105916B2 (en) 2003-06-11 2011-09-26 Bicycle component and method for manufacturing such a component

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EP20030425530 EP1486413B1 (de) 2003-06-11 2003-08-01 Verfahren zur Herstellung einer Fahrradkomponente

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US13/245,351 Continuation US10105916B2 (en) 2003-06-11 2011-09-26 Bicycle component and method for manufacturing such a component

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US8777162B2 (en) * 2006-12-08 2014-07-15 Airbus Operations Gmbh Connecting rod for the structural reinforcement of a fuselage structure of an aircraft
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US9428005B2 (en) * 2012-12-21 2016-08-30 Campagnolo S.R.L. Bicycle component comprising a body made from aluminium and a body made from composite material, and method for manufacturing such a component
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US11485449B2 (en) 2015-09-01 2022-11-01 The Hive Global, Inc. Bicycle cassette with locking connection
US11142280B2 (en) 2016-03-24 2021-10-12 The Hive Global, Inc. Bicycle crank with spindle attachment structure
US11485184B2 (en) * 2017-08-04 2022-11-01 Zf Friedrichshafen Ag Three-point suspension link and production method for a three-point suspension link
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US10919359B2 (en) * 2017-12-04 2021-02-16 Dr. Ing. H.C. F. Porsche Aktiengesellschaft Connecting strut
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US20190168564A1 (en) * 2017-12-04 2019-06-06 Dr. Ing. H.C. F. Porsche Aktiengesellschaft Connecting strut
US11440364B2 (en) * 2017-12-13 2022-09-13 Zf Friedrichshafen Ag Method for producing a component, and component
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EP1486413A2 (de) 2004-12-15
TWI391288B (zh) 2013-04-01
CN1572650A (zh) 2005-02-02
TWI326661B (en) 2010-07-01
EP1486413B1 (de) 2010-04-28
TW200502130A (en) 2005-01-16
TW201016540A (en) 2010-05-01
US10105916B2 (en) 2018-10-23
EP2110302A1 (de) 2009-10-21
EP2130756B1 (de) 2012-10-03
CN1572650B (zh) 2010-04-28
JP4836413B2 (ja) 2011-12-14
JP2005001662A (ja) 2005-01-06
EP2130756A1 (de) 2009-12-09
US20050012298A1 (en) 2005-01-20
US20120064284A1 (en) 2012-03-15
EP1486413A3 (de) 2004-12-29

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